Car top carrier

ABSTRACT

The invention provides improvements for an enclosed carrier configured for mounting on top of a car.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is based upon and claims priority under 35U.S.C. §119 from U.S. Provisional Patent Application Ser. No. 60/443,487filed Jan. 28, 2003 and from U.S. patent application Ser. No. 10/662,123filed Sep. 11, 2003, each of which is incorporated herein by referencein its entirety for all purposes.

FIELD OF THE INVENTION

[0002] The invention relates to assemblies for carrying cargo on avehicle. In particular, the invention provides improvements for a box ortrunk designed for mounting on top of a car.

BACKGROUND OF THE INVENTION

[0003] In recent years car top carriers in the form of boxes or trunkshave become quite popular. Enclosed carriers are preferable overconventional open racks for a variety of reasons. Enclosed carriersprotect cargo from the elements such as wind, rain, and snow. Enclosedcarriers are also more secure from theft or vandalism.

[0004] However, some car top boxes have problems which make themdifficult or cumbersome to use. For example, some boxes use a laborintensive bracket system to secure the box on to the crossbars of avehicle roof rack. Bracket systems typically require the installer toreach extensively over the top of the car. Such bracket systems areimpractical, particularly for a short person. The installer may have topractically climb into the open box to secure the brackets. This isespecially a problem for a user who frequently wants to install orremove the carrier from the car.

[0005] Another problem with some enclosed car top carriers is that theycan only be accessed from one side. Depending on where or how thevehicle is parked, or who is trying to access the carrier, it may beinconvenient or awkward to always access the box from the same side.

[0006] Another problem with car top trunks or boxes is that they aresometimes difficult to open. Typically, there are several latches on theside of the box that opens. The user may have to operate multiplelatches simultaneously where the latches are separated by a longdistance. This may require substantial strength, dexterity, and reach.Some boxes have an actuator that coordinates simultaneous release ofmultiple latches but still may require special handling such as liftingof the cover while manipulating the actuator or handle. Accordingly,there is a need for enclosed car top carriers that are easy to mount ona vehicle and easy to use.

SUMMARY OF THE INVENTION

[0007] An example of the invention uses a mounting assembly that isquick and easy to install on a car. A preferred design uses acam-operated clamping device to grip crossbars on a vehicle rack.Another example of the invention uses coordinated hinge/latch devices topermit easy opening of the carrier from either side of a vehicle. Otherexamples and aspects of the invention are described in detail below.

BRIEF DESCRIPTION OF DRAWINGS

[0008]FIG. 1 is a side view of a car top carrier mounted on a vehicle.

[0009]FIG. 2 is an exploded view of a car top carrier.

[0010]FIG. 3 is a partial cut-away view of clamp 34 c in FIG. 1 grippinga crossbar.

[0011]FIGS. 4 and 5 are partial cut-away side views of the clamp in FIG.3 as the cam lever moves toward the release position.

[0012]FIG. 6 is a top view of the clamp in FIG. 3.

[0013]FIG. 7 is an end-on view of the clamp in FIG. 3.

[0014]FIG. 8 is an inside view of a car top carrier with four clampsganged together.

[0015]FIG. 9 is an inside view of a car top carrier with two clampsganged together.

[0016]FIGS. 10 and 11 are end views of a car top carrier showing openingof the box from opposing sides.

[0017]FIGS. 12-14 are side views of a hinge/latch mechanism, forexample, as shown in FIG. 2.

[0018]FIG. 15 is a partial cut way view of a hinge/latch mechanism, forexample, as shown in FIG. 2.

[0019]FIGS. 16-18 are partial cut away views of a hinge/latch mechanismin operation.

[0020]FIG. 19 is an isolated side view of a lid support device, forexample, as shown in FIG. 2.

DESCRIPTION OF THE INVENTION

[0021]FIG. 1 shows car top carrier 20 mounted on vehicle 22. Car topcarrier 20 includes top 24 and bottom 26 mounted on crossbars 28 on thetop of car 22.

[0022]FIG. 2 shows an exploded view of car top carrier or box 20.Mounting hardware is provided for easily securing carrier 20 to thevehicle rack. For example, four mounting mechanisms 34 a-d may beprovided for this purpose. Each mounting mechanism includes a cam leverfor operating a jaw mechanism to clamp around a crossbar, as explainedin more detail below. The clamps may be provided completely preassembledwith the box. The clamps never need to be disassembled as the carrier isput on and off one or more cars through the life of the product. Eachclamp may be adjustable to grip, with variable force, crossbars ofdifferent dimensions. The clamps may also be adjustable to differentlocations on the floor of the box, for example, along an axis parallelto the direction of vehicle travel. The clamps are preferably configuredso that once the carrier clamps are adjusted for a particular vehicleconfiguration, the carrier can be easily installed or removed by simplymanipulating each cam lever with a single, one step, switch, toggle,rotation, stroke or other quick-action, for example, with an over-centerassist mechanism.

[0023] Sets of hinge/latch mechanisms may also be provided on each sideof carrier 20 to allow opening of the carrier from opposite sides. InFIG. 2, hinge/latch mechanisms 40 a-40 c are mounted on one side ofcarrier 20 to connect top 24 to bottom 26. Similarly, on the other sideof carrier 20, hinge/latch mechanisms 42 a-42 c connect top 24 to bottom26. Actuating bar 44 is mounted inside carrier 20 for operating andsynchronizing hinge/latch function of mechanisms 40 a-40 c. Actuatingbar 44 may be operated, i.e., moved forward and backward relative to thelong axis of carrier 20, by manipulating switch, handle, or key device46 from the exterior of carrier 20. A similar actuating bar (not shown)is used to operate hinge/latch mechanisms 42 a-c via switch, handle, orkey device 50.

[0024] Lid supports 54 a and 54 b are mounted at the front and back endsof carrier 20, connecting top 24 to bottom 26. Lid supports 54 a and 54b stabilize top 24 when moving between open and closed positions. Lidsupports 54 a and 54 b may also limit the extent of potential opening ofcarrier 20. For example, lid supports 54 a, 54 b, may limit the extentof opening on either side of carrier 20 to approximately 16-inches.Longitudinal ribs or indentations 58 may be formed in carrier top 24 toprovide stiffening and increased strength for carrier 20, and may alsobe desirable aesthetically.

[0025]FIGS. 3-7 show details of one of the four mounting mechanisms, forexample, as shown in FIG. 2. FIG. 3 is a side view of one of clamps 34,with a portion of bottom 26 of carrier 20 cut-away. In closed position,cam lever 38 seats against floor 33 of bottom 26. Cam lever 38 actsthrough cam portion 41, shaft member 43, bolt 45, barrel nut 47, andaxle 49 to apply a force holding crossbar 28 tightly clamped betweenmovable jaw portion 51 and stationary jaw portion 53.

[0026]FIGS. 4 and 5 show details of clamp 34 moving to an unclampedposition. Cam lever 38 pivots around shaft member 43. The shape of camportion 41 and the position of shaft member 43 causes opening andclosing of movable jaw portion 51 relative to stationary jaw portion 53when cam lever 38 is rotated between different positions as shown inFIGS. 3 to 5. The jaw portions may define openings of different shapesfor various purposes. The jaw portions in FIGS. 3-5 define an elongatecurved opening, or oval shape to accommodate crossbars having differentcross-sectional shapes. Cam portion 41 is shaped so that as lever 38rotates around shaft member 43 the distance between shaft member 43 andfloor 33 is altered, thus causing corresponding pivotal movement of jawportion 51 toward or away from fixed stationary jaw potion 53 mounted onfloor 33. An over-center mechanism is used so that a maximum height ofshaft member 43 is reached at an intermediate point, for example,approximately at the location shown in FIG. 4. This way lever 38 tendsto stay locked in the closed position shown in FIG. 3, and tends tospring to the unlocked position when lever 38 is moved over-center inthe opposite direction, as shown in FIG. 5. Movable jaw portion 51pivots around axle structure 49. Movable jaw portion 51 is elongate,with an initial portion 55 angled so as to guide crossbar 28 intoposition between movable jaw portion 51 and stationary jaw portion 53.Movable jaw portion 51 has a concave inner surface 57 which contactscrossbar 28 when the jaw is closed, and which is configured forgripping. Concave inner surface 57 may have a cushion or pad 59 nearaxle 49. Stationary jaw portion 53 may have side tabs 61 to guidemovable jaw portion 51 when clamp 34 is moved to the closed position.

[0027] Clamp 34 is mounted on floor 33 of carrier bottom 26 by bolt 45,with barrel nut 47 serving us an anchor pivot for bolt 45. In addition,a first oversize knob 63 turns bolt 45 to move barrel nut 47 closer toor farther away from shaft member 43, thereby providing a grossadjustment mechanism for the tightness of the clamping action. Movablejaw portion 51 clamps around crossbar 28. In FIGS. 3-5, arrow 64indicates the direction of forward travel of vehicle 26. Movable jawportion 51 preferably is oriented to open in the forward direction tomake carrier 20 less likely to be dislodged from vehicle 22 in ahigh-impact forward collision.

[0028]FIG. 6 shows a top view of clamp 34. Bolt 45 passes from theinside of car top carrier 20 to the outside through floor 33 of carrierbottom 26 via slot 66 which is aligned with the long axis of car topcarrier 20. Slot 66 allows adjustment of the location of clamp 34 alongthe long axis of car top carrier 20. Finger tabs 68 facilitate prying orlifting of cam lever 38 away from floor 33 when opening clamp 34. Camlever 38 is shaped to provide clearance for first oversize knob 62 whencam lever 38 is moved between open and closed positions. A secondoversize knob 70 provides for tightening or loosening of fastener 72passing through slot 66 to stationary jaw component 53 to prevent orallow motion of clamp 34 in slot 66. Floor 33 of bottom 30 is shaped inthe form of a ridge or rail 74 to complement the shape of clamp 34 andto aid in seating cam lever 38 against floor 33 when clamp 34 is in theclosed position, thereby providing repeatable and secure alignment.

[0029]FIG. 7 is an end-on view of clamp 34, as shown in FIG. 6. Shaftmember 43 may include curvature away from barrel nut 47 so as to providespring action during operation of clamp 34.

[0030]FIG. 8 shows a top view of the interior of car top carrier 80including four clamps 82 a-d. In this example, all four clamps 82 a-dare ganged by connectors 84 and 86. Ganging clamps allows multipleclamps to be operated with a single movement, step, or manipulation.Ganged clamp configurations may also make it easier to operate clampslocated distally from the installer's vantage point.

[0031]FIG. 9 shows another example. A top view of car top carrier 90 hastwo clamps 92 a and 92 b. In this example, two clamps 92 a and 92 b arelocated on front and rear crossbars, and are ganged by connector 94 sothat clamps 92 a and 92 b open and close together.

[0032] Any number of clamps may be used to fasten a container on a setof crossbars on top of a vehicle. For example, one, two or more clampsmay be used to secure a container on a front crossbar. Similarly, one,two or more clamps may be used to secure a container to a rear crossbar.For some purposes a single clamp may be sufficient, for example, on thefront crossbar with the container merely resting on the back crossbar.In other instances, a single clamp may be used on each crossbar, ormultiple clamps may be used on one or both crossbars.

[0033] Any combination of clamps may be ganged. For example, it may beadvantageous to have a clamp which is closest to the hinge side of a box(distal clamp) ganged to a clamp on the opening side of the box(proximal clamp) so that operation of the proximal clamp automaticallyoperates a corresponding distal clamp.

[0034] It may also be advantageous to have an extended handle oractuator connected to the distal clamp so that the distal clamp can beoperated with minimal reaching from the open side of the container.

[0035] A clamp, as described above, may also be modified to provideautomatic clamping. For example, the movable jaw portion may be springbiased toward the closed position. The lip of the jaw may be configuredto cause opening of the jaw as the box slides forward across the top ofthe crossbars. Once the jaw encompasses the crossbar, it springs back toa secure closed position. The jaw is further configured so that itcannot be opened without a manipulation, for example, switch orlever-operated, action inside the box. This type of fastener may bereferred to as “seat belt type engagement.”

[0036] A jaw member as described above, may have different shapes. Forexample, the jaw member may be generically shaped to fit arounddifferently shaped or dimensioned crossbars. Alternatively, the jawmember may be custom-shaped to fit around a specific crossbarconfiguration. For example, the jaw member may have a partiallyrectangular inner surface for fitting around a rectangular or squarecross bar.

[0037] Clamping devices should be designed to minimize manufacturingcosts and complexity. For example, a rail with a slot, as describedabove, may be molded into the floor of a box. A stationary jaw portion,movable jaw portion, and cam lever may be separately molded pieces.

[0038] Different kinds of actuators may be used to operate the jawassembly. For example, an actuator may be a differently-shaped cam, ormay be a screw mechanism using a threaded member. A cam lever mayoperate in different directions other than parallel to the long axis ofa container as described above. Clamp mechanisms, as described above,may also be implemented to connect other types of apparatus to crossbarson top of a vehicle.

[0039] The clamp mechanisms shown and described herein may beimplemented on boxes with any type of hinge and/or latch mechanism. Forexample, the clamping devices may be used on a box with dual functioninghinges that can operate as a hinge or a latch, for example, as describedin U.S. Pat. No. 5,823,411 and U.S. Provisional Patent Application No.60/443,437, each of which is hereby incorporated by reference in itsentirety.

[0040]FIGS. 10 and 11 show end views of car top carrier 20 openedalternately from opposite sides. This feature of carrier 20 is madepossible by dual-functioning hinge/latch mechanisms such as the examplesdescribed in detail below.

[0041]FIGS. 12 and 13 are side views of a hinge/latch mechanism, forexample, like 40 a-c and 42 a-c in FIG. 2. Mounting base, platform, orportion 110 may be securely fastened, for example, by screws to 24 ofcarrier 20. Receiving portion 120 may be fastened securely to acorresponding location on bottom 26 of carrier 20. In FIG. 12hinge/latch mechanism 40 a is oriented in position for securing top 32to bottom 34 when carrier 20 is closed. FIG. 13 shows the orientation ofhinge/latch mechanism 40 when the hinge/latch mechanisms on the oppositeside of the box are functioning as a latch. Flared portion 140 ofreceiving portion 120 permits a selected degree of motion of arm portion112 relative to receiving portion 120. FIG. 14 shows hinge/latchmechanism 40 operating as a latch after enlarged end portion 114 hasbeen released from receiving portion 120.

[0042]FIG. 15 shows a cut-away view of hinge/latch mechanism 40 withactuating bar 44 removed. Plunger 150 is spring-biased upward againstenlarged end portion 114. The spring helps the lid to pop up initiallywhen opening the container. As shown, enlarged end portion 114 has aspherical shape which allows mounting platform 110 multiple, eveninfinite, degrees of movement relative to receiving portion 120. Thisfeature allows the hinge/latch device, not only the flexibility ofacting as a hinge or a latch, but also permits the same hinge/latchconfiguration to be used on carriers of many different shapes andgeometries. When pawl 122 is rotated in the direction of arrow 152 andis sufficiently out of the way of enlarged end portion 114, plunger 150urges enlarged end portion 114 upward so that it disengages fromreceiving portion 120 even when pawl 122 is permitted to rotate back toits original orientation. The spring and plunger mechanism makes iteasier to open the carrier because once the actuating bar hassimultaneously pushed multiple pawl members out of the way in each ofthe coordinated hinge/latch mechanisms, the latches are disengagedwithout further manual movement or handling relative to carrier top 24.To re-engage hinge/latch mechanism 40 a, enlarged end portion 114 isforced into receiving portion 120 until pawl 122 is pushed asideallowing enlarged end portion 114 to “snap” into place, as shown in FIG.15. The springs may be selected such that very little, if any, manualforce is required, in addition to gravity, to latch the top closed,somewhat analogous to the closing of a trunk on a car.

[0043]FIGS. 16-18 show movement of actuating bar 44 to disengageenlarged end portion 114 from receiving portion 120. As shown in FIG.16, actuating bar 44 has a projection 160 that is normally spaced awayfrom end portion 162 of pawl member 122 when hinge/latch mechanism 40 ais functioning as a hinge. When actuating bar 144 is moved in thedirection of arrow 164 in FIG. 17, projection 160 of actuating bar 144contacts and pushes end portion 162 of pawl member 122. This eventuallycauses rotation of pawl member 122 out of the way of the main receivingchannel in receiving portion 120, thus allowing enlarged end portion 114to disengage receiving portion 120, enabling hinge/latch mechanism 40 ato function as a latch.

[0044]FIG. 19 shows a lid support, for example, such as 54 b in FIG. 2.First arm 202 may be connected to bottom 26 of carrier 20. Second arm204 may be connected to top 24 of carrier 20. First arm 202 is pivotallyconnected second arm 204. Spring 206 is contained in a pocket in firstarm 202. Spring 206 acts on slide or cam follower 208 which moves up anddown as second arm 204 is moved between open and closed positions.Second arm 204 has a cam portion 210 than contacts slide 208. The shapeof cam portion 206 determines the magnitude and direction of torqueexerted on second arm 204 about pivot point 212.

[0045] While the present invention has been particularly shown anddescribed with reference to the foregoing preferred embodiments, thoseskilled in the art will understand that many variations may be madetherein without departing from the spirit and scope of the invention asvariously described and defined above. The description of the inventionshould be understood to include all novel and non-obvious combinationsof elements described herein.

We claim:
 1. A car top carrier comprising: a box having a lid and abottom, a clamp device configured to attach the bottom of the box to apair of crossbars on top of a car, one or more hinge devices releaseablyconnecting the lid to the bottom, each hinge having a first portionsecured to the lid, and a second portion secured to the bottom, thehinge being configured to permit pivotal rotation of the lid along anedge portion of the bottom, and being provided with a release mechanismso that the hinge device can also function as a latch allowingseparation of the first and second portions of the hinge device, whereinthe hinge device automatically snaps into engagement when the firstportion is urged toward the second portion.
 2. The carrier of claim 1,wherein one of the first and second portions has a catch, and the otherportion has an enlarged structure configured for receipt by the catch.3. The carrier of claim 2, wherein the catch is spring biased toward aclosed position which permits entry of the enlarged structure into thecatch but does not allow exit of the enlarged structure from the catchwithout manipulation.
 4. The carrier of claim 2, wherein the catchincludes a pawl that is spring biased toward a constricted-passageposition.
 5. The carrier of claim 4, wherein the pawl can be pushedaside by the enlarged structure upon entry but not upon exit of thecatch.
 6. A car top carrier comprising: a box having a lid and a bottom,a clamp device configured to attach the bottom of the box to a pair ofcrossbars on top of a car, one or more hinge devices releasablyconnecting the lid to the bottom, each hinge having a first portionsecured to the lid, and a second portion secured to the bottom, thehinge being configured to permit pivotal rotation of the lid along anedge portion of the bottom, and being provided with a release mechanismso that the hinge device can also function as a latch allowingseparation of the first and second portions of the hinge device, whereinone of the first and second portions has a catch, and the other portionhas an enlarged structure configured for receipt by the catch.
 7. Thecarrier of claim 6, wherein the catch is spring biased toward a closedposition which permits entry of the enlarged structure into the catchbut does not allow exit of the enlarged structure from the catch withoutmanipulation.
 8. The carrier of claim 6, wherein the enlarged structureis substantially spherical so that the hinge device permits the firstand second portions to be mounted on various lid and bottom shapes. 9.The carrier of claim 6, wherein the catch is provided with a spring thaturges the enlarged structure to disengage when catch is manipulated toan open position.
 10. The carrier of claim 6 further comprising firstand second lid supports, each lid support connecting the lid to thebottom.
 11. The carrier of claim 10, wherein each lid includes a slidermounted on a spring, and a cam slidably contacting the slider so thatthe lid support assists in opening and closing the lid.
 12. The carrierof claim 6, wherein the first portion has the enlarged structure and thesecond portion has the catch.
 13. The carrier of claim 6, wherein thefirst portion has the catch and the second portion has the enlargedposition.
 14. The carrier of claim 6, wherein the second portion has areceptacle with a flared lip allowing a limited amount of hingerotation.
 15. The carrier of claim 6, wherein the catch includes a pawlthat is spring biased toward a constricted-passage position.
 16. Thecarrier of claim 15, wherein the pawl can be pushed aside by theenlarged structure upon entry but not upon exit of the catch.
 17. A cartop carrier comprising: a box having a lid and a bottom, a clamp deviceconfigured to attach the bottom of the box to a pair of crossbars on topof a car, one or more hinge devices releasably connecting the lid to thebottom, each hinge having a first portion secured to the lid, and asecond portion secured to the bottom, the hinge being configured topermit pivotal rotation of the lid along an edge portion of the bottom,and being provided with a release mechanism so that the hinge device canalso function as a latch allowing separation of the first and secondportions of the hinge device, the first and second portions beingconfigured to permit relative rotation around at least two axes.
 18. Thecarrier of claim 17, wherein the clamp device includes at least one camlever positioned inside the box for opening and closing the clamp devicesecurely around a crossbar.